Image-stitching for dimensioning

ABSTRACT

Dimensioning systems may automate or assist with determining the physical dimensions of an object without the need for a manual measurement. A dimensioning system may project a light pattern onto the object, capture an image of the reflected pattern, and observe changes in the imaged pattern to obtain a range image, which contains 3D information corresponding to the object. Then, using the range image, the dimensioning system may calculate the dimensions of the object. In some cases, a single range image does not contain 3D data sufficient for dimensioning the object. To mitigate or solve this problem, the present invention embraces capturing a plurality of range images from different perspectives, and then combining the range images (e.g., using image-stitching) to form a composite range-image, which can be used to determine the object&#39;s dimensions.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application claims the benefit of U.S. patent application Ser. No.14/870,488 for Image-Stitching for Dimensioning filed Sep. 30, 2015 (andpublished Apr. 14, 2016), now U.S. Pat. No. 10,096,099, which claims thebenefit of U.S. Patent Application Ser. No. 62/062,175 for System andMethods for Dimensioning, (filed Oct. 10, 2014). Each of the foregoingpatent applications, patent publication, and patent is herebyincorporated by reference in its entirety.

FIELD OF THE INVENTION

The present invention relates to systems for determining an object'sphysical dimensions (i.e., dimensioning systems) and, more specifically,to a dimensioning system that uses image-stitching to acquire the datanecessary for dimensioning.

BACKGROUND

Determining an item's dimensions is often necessary as part of alogistics process (e.g., shipping, storage, etc.). Physically measuringobjects, however, is time consuming and may not result in accuratemeasurements. For example, in addition to human error, measurementerrors may result when measuring irregularly shaped objects or whencombining multiple objects into a single measurement. As a result,dimensioning systems have been developed to automate, or assist with,this measurement.

A dimensioning system typically senses an object's shape/size inthree-dimensions (3D) and then uses this 3D information to compute anestimate of an object's dimensions (e.g., volume, area, length, width,height, etc.). In addition, for irregular objects (or multiple objects),the dimensioning system may compute the dimensions of a minimum boundingbox (MVBB) that contains the object (or objects).

The dimensioning system may sense an object by projecting a lightpattern (i.e., pattern) into a field-of-view. Objects within thefield-of-view will distort the appearance of the light pattern. Thedimensioning system can capture an image of the reflected light-patternand analyze the pattern distortions in the captured image to compute the3D data necessary for dimensioning.

Accurate dimensioning requires images with (i) high pattern visibilityand (ii) high pattern density. In some cases, however, the pattern ishard to resolve. For example, the pattern may be obscured by the shapeof the object, or by the object's color (i.e., reflectivity). In othercases, the lighting in the environment may obscure the pattern in thecaptured images (e.g., under exposure or over exposure). In still othercases, the object may be larger than the dimensioning system'sfield-of-view. While moving the dimensioning system away from the objectmay help fit the object within the field-of-view, this comes at theexpense of pattern density because the projected pattern spreads as therange between the object and the dimensioning system is increased.

In digital photography image-stitching is the process of combiningimages to produce a larger, high-resolution image. Image-stitching maybe applied to dimensioning in order to increase the dimensioningsystem's field-of-view without sacrificing pattern density. In addition,image-stitching can help to resolve a pattern that was obscured in asingle image. Therefore, a need exists for image-stitching imagesacquired by a dimensioning system in order to better measure objects.

SUMMARY

Accordingly, in one aspect, the present invention embraces a method fordimensioning an object. In the method, a dimensioning system ispositioned so that at least a portion of an object is contained in thedimensioning system's field-of-view. The dimensioning system thencaptures a first range image of the field-of-view. After the first rangeimage is captured, either the dimensioning system or the object is movedso that the dimensioning system's field-of-view contains a differentportion of the object. Then, a second range image is captured. Thisprocess of moving the dimensioning system (or the object) and capturinga range images is repeated until a plurality of range images arecaptured. The plurality of range images are then combined to create acomposite range-image. The dimensions of the object are then determinedusing the composite range-image.

In a possible embodiment of the method, capturing a range image includes(i) using a pattern projector to project a light pattern into thefield-of-view, (ii) capturing an image of the reflected light-patternusing a range camera, and (iii) generating 3D data from the image of thereflected light-pattern.

In another possible embodiment of the method, capturing a range imageincludes (i) using a pattern projector to project a light pattern intothe field-of-view, (ii) capturing an image of the reflectedlight-pattern using a range camera, and (iii) generating 3D data fromthe image of the reflected light-pattern so that the plurality of rangeimages contain 3D sufficient for dimensioning the object. For example,3D data sufficient for dimensioning may imply that 3D data is collectedfrom all surfaces of the object. Alternatively, 3D data sufficient fordimensioning may imply that the 3D data from a surface of the object hasno gaps (i.e., no missing areas) in the reflected light-pattern.

In another exemplary embodiment of the method, the dimensioning systemis handheld.

In another exemplary embodiment of the method, audio and/or visualmessage are generated to guide the user in performing the movement ofthe dimensioning system or the object. For example, these audio and/orvisual messages can include instructions for the user to (i) move thedimensioning system (or the object) in a particular direction, (ii) movethe dimensioning system (or the object) at a particular speed, and/or(iii) cease moving the dimensioning system (or the object).

In another exemplary embodiment of the method, moving either thedimensioning system or the object includes an automatic movement of thedimensioning system (or the object).

In another exemplary embodiment of the method, combining the pluralityof range images to create a composite range-images includesimage-stitching the plurality of range images. In one possibleembodiment, the image-stitching includes simultaneous localization andmapping (SLAM).

In another aspect, the present invention embraces a dimensioning systemthat includes (i) a pattern projector, (ii) a range camera, and (iii) aprocessor that is communicatively coupled to the pattern projector andthe range camera. The pattern projector is configured to project a lightpattern onto an object, while the range camera is configured to capturean image of the reflected light-pattern. The range camera uses thereflected light-pattern to generate 3D data and uses the 3D data tocreate a range image.

The dimensioning system's processor is configured by software to triggerthe range camera to capture a plurality of range images and combine theplurality of captured range images to form a composite range-image.Then, using the composite range-image, the processor calculates thedimensions of the object.

In an exemplary embodiment of the dimensioning system, the plurality ofrange images are captured as the spatial relationship between thedimensioning system and the object is changed. For example, in oneembodiment, the dimensioning system is handheld and a user can move thedimensioning system so that each range image in the plurality of rangeimages includes 3D data from a portion of the object, and the compositerange-image includes 3D data from the entire object. In someembodiments, the processor is further configured by software to gathertracking/mapping information as the spatial relationship between therange camera and the object is changed. The tracking/mapping informationcan be used, in some embodiments, to generate messages to help a userchange the spatial relationship between the range camera and the object.These messages may be instructions to (i) move the dimensioning systemor the object in a particular direction, (ii) move the dimensioningsystem or the object at a particular speed, and/or (iii) cease movingthe dimensioning system or the object. After the plurality of rangeimages are captured, the processor can be configured by software tocreate a composite range-image by image-stitching the range images usingthe tracking/mapping information. In a possible embodiment, theplurality of range images for image-stitching have partially overlappingfields of view.

The foregoing illustrative summary, as well as other exemplaryobjectives and/or advantages of the invention, and the manner in whichthe same are accomplished, are further explained within the followingdetailed description and its accompanying drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 schematically depicts a block diagram of a dimensioning systemaccording to an embodiment of the present invention.

FIG. 2 graphically depicts the principle of sensing three dimensionsusing a spatially offset pattern projector and range camera according toan embodiment of the present invention.

FIG. 3 graphically depicts an implementation of a dimensioning system'spattern projector according to an embodiment of the present invention.

FIG. 4 graphically depicts the movement of either the dimensioningsystem and/or the object according to an embodiment of the presentinvention.

FIG. 5a graphically depicts a plurality of images, wherein eachconstituent image contains a portion of an object.

FIG. 5b graphically depicts a composite image of the object formed byimage-stitching the constituent images shown in FIG. 5 a.

FIG. 6 graphically depicts a flow diagram illustrating a method fordimensioning an object according to an embodiment of the presentinvention.

DETAILED DESCRIPTION

The present invention embraces the use of image-stitching to create acomposite range-image for dimensioning. Some advantages of usingcomposite images for dimensioning are (i) better pattern coverage of anirregular object or group of objects, (ii) greater accuracy (i.e.,higher pattern density), and (iii) immunity to lighting effects, such asshadows or bright reflections.

An exemplary dimensioning system is shown in FIG. 1. The dimensioningsystem 10 includes a pattern projector 1 that is configured to project alight (e.g., infrared light) pattern into a field-of-view 2. The lightpattern typically comprises points of light arranged in a pattern (i.e.,point cloud). The points of light may be (i) sized identically ordifferently and (ii) may be arranged in some order or pseudo-randomly.The pattern projector may create the light pattern using a light source(e.g., laser, LED, etc.), a pattern creator (e.g., a mask, a diffractiveoptical element, etc.), and one or more lenses.

The dimensioning system 10 also includes a range camera 3 configured tocapture an image of the projected light pattern that is reflected fromthe range camera's field-of-view 4. The field-of-view of the rangecamera 4 and the field-of-view of the pattern projector 2 should overlapbut may not necessarily have identical shapes/sizes. The range camera 3includes one or more lenses to form a real image of the field-of-view 4onto an image sensor. Light filtering (e.g., infrared filter) may bealso be used to help detect the reflected pattern by removing straylight and/or ambient light. An image sensor (e.g., CMOS sensor, CCDsensor, etc.) is used to create a digital image of the light pattern.The range camera may also include the necessary processing (e.g. DSP,FPGA, ASIC, etc.) to obtain 3D data from the light pattern image.

As shown in FIG. 2, the pattern projector 1 and the range camera 3 arespatially offset (e.g., stereoscopically arranged). The spatial offset 8allows for changes in the range 5 of an object 6 to be detected as animage offset 7 on the range camera's image sensor. The spatial offset 8may be adjusted to change the image offset 7 to change the resolution atwhich range differences 5 may be detected. In this way, image offsets inthe point-cloud pattern may be converted into 3D data for objects withinthe dimensioning system's field-of-view.

The 3D data includes range values for each point of light in thepoint-cloud image. Further, range values between the points of light inthe point-cloud image may be interpolated to create what is known as arange image. A range image is a gray scale image in which each pixelvalue in the image corresponds to an estimated range between thedimensioning system and a point in the field-of-view. The range cameramay output 3D data in the form of point-cloud images or range images.

A range image may be analyzed using software algorithms running on thedimensioning system's processor 9 to detect objects and determine theobject's dimensions. In some cases these algorithms may include steps tocreate a minimum bounding box (MVBB), which is a computer model of a boxthat surrounds an object (e.g., an irregularly shaped object) or acollection of objects (e.g., multiple boxes on a pallet). In this case,the dimensioning system may return the dimensions of the MVBB.

Accurate dimensioning requires high-quality images of the reflectedpattern (i.e., point-cloud images). A high quality point-cloud image isone in which the points of light in the pattern are visible on aplurality of the object's surfaces. Low quality point-cloud images mayresult from a variety of circumstances. For example, the imaged patternmay not be visible one or more surfaces (e.g., surfaces that are blockedfrom the pattern projector) or fall outside the field-of-view of eitherthe pattern projector and/or the range camera. In another example, thelight pattern may be partially visible on a surface and/or lacksufficient pattern density (i.e., the number of visible points of lighton the surface). In yet another example, the lighting (e.g., glare,shadows) in the object's environment and/or the object's reflectivity(e.g., dark objects) may adversely affect the visibility of the lightpattern.

FIG. 3 graphically depicts a dimensioning system 10 projecting a lightpattern 11 onto an object 6. Here the object is larger than the patternprojector's field-of-view 2. As a result, portions of the object do notintersect with the projected light-pattern 11. Since dimensioning relieson sensing the image offset of the projected light-pattern, no 3D datacan be created for the portions of the object that do not intersect withthe projected light-pattern 11.

The present invention mitigates or solves these problems by capturing aplurality of point-cloud images (or range images) from differentperspectives and then combining the plurality of point-cloud images (orrange images) into a composite point-cloud image (or range image).

FIG. 3 illustrates how the movement of the dimensioning system 10 and/orthe object 6 may help capture (i.e., sense, sample, etc.) 3D data. Themovement allows for the capture of 3D data from more portions of theobject than could be obtained with a single range image having afield-of-view 2 smaller than the object 6.

Range images may be captured during the movement and then combined toform a composite range-image. The composite range-image has 3D data frommore points on the object. For example, all sides of an object may besampled during the moving process to obtain 3D data from the entireobject. Further, gaps in the pattern (i.e., missing areas in thepattern) may be filled in using this technique.

In one possible embodiment, the movement of the dimensioning systemand/or the object is automatic and does not require user participation.In this embodiment, the dimensioning system may be coupled to movementdevices (e.g., actuators, motors, etc.) that adjust the spatialrelationship between the dimensioning system and the object. In oneexample, the object 6 may be placed in a measurement area and thedimensioning system 10 may be moved around the object 12 to collectrange images from various perspectives as shown in FIG. 4. In anotherexample, a fixed dimensioning system may collect range images as anobject 6 is rotated (e.g., on a motorized turntable) 13 as shown in FIG.4. In these cases, position information may be obtained from themovement device and used to help combine the range images.

In another possible embodiment, the movement of the dimensioning systemand/or the object is performed by a user. Here messages (e.g., audio,visual, etc.) may be generated by the dimensioning system's processorand conveyed to a user interface (e.g., screen, indicator lights,speaker, etc.). The user may follow the instructions provided by themessages to move the dimensioning-system/object. The instructions mayinclude messages to help a user know (i) how far to move thedimensioning-system/object, (ii) how fast to move thedimensioning-system/object, (iii) to move the dimensioning system/objectto a particular location, and (iv) how long to continue moving thedimensioning-system/object (e.g., when to stop moving). For example, thedimensioning system may be handheld and the user may move thedimensioning system to change perspective. In this case, thedimensioning system may be configured to gather tracking information(e.g., sense its position and orientation within the environment) tohelp combine the range images.

In general, the dimensioning system may be moved in a variety of ways asthe range images are captured. In some cases, however, this movement mayhave certain requirements to facilitate combining. For example,movements may be limited to movements having a constant range betweenthe dimensioning system and the object, as changes in range can affectthe image size of the light-pattern/object. In another example, themovement may be limited to a certain path having a particular startingpoint and ending point. This path may be determined using an expectedobject size/shape.

The requirements for movement may be reduced through the use ofsimultaneous localization and mapping (SLAM). SLAM is a computeralgorithm that uses images (e.g., range images) of an environment toupdate the position of the imager (e.g., dimensioning system). Whenmoving a dimensioning-system, for example, SLAM algorithms may detectfeatures (i.e., landmarks) in a captured range image and then comparethese landmarks to landmarks found in previously captured range imagesin order to update the position of the dimensioning system. Thisposition information may be used to help combine the range images.

Combining range images is typically achieved using image-stitching.Image-stitching refers to computer algorithms that transform, register,and blend a plurality of constituent images to form a single compositeimage. The image-stitching algorithms may first determine an appropriatemathematical model to relate the pixel coordinates for constituentimages to the pixel coordinates of a target composite-image surface(e.g., plane, cylinder, sphere, etc.). This involves transforming (e.g.,warping) the images to the target composite-image surface. Thetransformed images may then registered to one another (e.g., usingfeature detection and mapping) and merged (e.g., blended) to remove edgeeffects.

The process and results of image-stitching are illustrated in FIG. 5aand FIG. 5b . As shown in FIG. 5a , four constituent images 14 a, 14 b,14 c, 14 d of an object 6 are captured. Each of the four images containsa different portion of the object 6. FIG. 5b illustrates the result ofimage-stitching the four constituent images. The composite image 15contains the entire object 6.

While range images have pixels to representing range instead ofreflected light, they are like conventional digital images in most otherregards. As such, the principles of image-stitching described thus farmay be applied equally to range images (or point-cloud images).

FIG. 6 graphically depicts a flow diagram illustrating a method fordimensioning an object using image-stitching. The method begins withpositioning 20 a dimensioning system so that at least a portion on anobject is contained within the dimensioning system's point-of-view andcapturing 30 a range image. The dimensioning system and/or the object isthen moved 60 so that another portion of the object is within thefield-of-view and another range image is captured 30. This process ofmoving and capturing is repeated until a plurality of range images iscaptured 40. The number of range images in the plurality of range imagesmay be a predetermined number or may be determined based on the motionof the dimensioning system/object. The plurality of range images arethen combined 70 to form a composite range-image, and the compositerange-image is used to dimension 90 the object.

In one exemplary embodiment, the dimensioning system may create messages50 to guide the movement of the dimensioning system and/or the object asdescribed previously.

In another exemplary embodiment, the dimensioning system may create orupdate the composite range-image in real time. In this case, thedimensioning system may be able to examine the latest compositerange-image to determine if there is 3D data sufficient for dimensioning(i.e., if a sufficient number of range images have been acquired) 80. Ifnot, the dimensioning system may create messages to help the user moveand capture range images so as to gather the missing or incomplete 3Ddata.

To supplement the present disclosure, this application incorporatesentirely by reference the following commonly assigned patents, patentapplication publications, and patent applications:

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In the specification and/or figures, typical embodiments of theinvention have been disclosed. The present invention is not limited tosuch exemplary embodiments. The use of the term “and/or” includes anyand all combinations of one or more of the associated listed items. Thefigures are schematic representations and so are not necessarily drawnto scale. Unless otherwise noted, specific terms have been used in ageneric and descriptive sense and not for purposes of limitation.

The invention claimed is:
 1. A method, comprising: projecting, using apattern projector, a light pattern into a field-of-view of a rangecamera of a dimensioning system, the field-of-view comprising a portionof an object; capturing, using the range camera of the dimensioningsystem, a range image of the field-of-view, wherein each pixel of therange image represents a distance from the range camera to a respectivepoint in the range camera's field-of-view, wherein the range image iscreated by determining a range value for each point of light in theprojected light pattern to generate a point-cloud image andinterpolating range values between points of light in the point-cloudimage; moving the dimensioning system and/or the object so that there isrelative movement between the dimensioning system and the object, andthe range camera's field-of-view contains a different portion of theobject; repeating the capturing and the moving until a plurality ofrange images have been captured, wherein in each range image of theplurality of range images, each pixel of the range image represents adistance from the range camera to a respective point in the rangecamera's field-of-view; gathering information as a spatial relationshipbetween the range camera and the object is changed, and the informationis selected from the group consisting of tracking information andmapping information; combining the plurality of range images to create acomposite range-image by image-stitching the plurality of range imagesusing the information gathered as the spatial relationship between therange camera and the object is changed; and dimensioning the objectusing the composite range-image, wherein dimensioning the object usingthe composite range-image comprises creating a minimum bounding box thatsurrounds the object; and returning the dimensions of the minimumbounding box as dimensions of the object.
 2. The method of claim 1,wherein range images in the plurality of range images have partiallyoverlapping fields of view.
 3. The method of claim 1, wherein thefield-of-view of the range camera and a field-of-view of the patternprojector overlap.
 4. The method of claim 3, wherein the field-of-viewof the range camera and the field-of-view of the pattern projector donot have the same shape and/or size.
 5. The method of claim 1,comprising generating messages to help a user change the spatialrelationship between the range camera and the object using the gatheredinformation.
 6. The method of claim 5, wherein the messages compriseinstructions to take action, and the instructions to take action areselected from the group consisting of instructions to (i) move thedimensioning system or the object in a particular direction, (ii) movethe dimensioning system or the object at a particular speed, and (iii)cease moving the dimensioning system or the object.
 7. The method ofclaim 1, wherein the light pattern comprises points of light arranged ina pseudo-random pattern.
 8. The method of claim 1, wherein the lightpattern comprises points of light having different sizes.
 9. The methodof claim 1, comprising moving the dimensioning system and/or the objectso that there is a constant range between the dimensioning system andthe object.
 10. The method of claim 1, comprising moving thedimensioning system and/or the object along a certain path having aparticular starting point and ending point.
 11. The method of claim 10,comprising determining the certain path using an expected object size,an expected object shape, or an expected object size and shape.
 12. Adimensioning system, comprising: a pattern projector configured toproject a light pattern onto an object; a range camera having a field ofview and configured to (i) capture an image of a reflected light-patternin the field of view, (ii) generate 3D data from the reflectedlight-pattern, and (iii) create a range image using the 3D data bydetermining a range value for each point of light in the projected lightpattern to generate a point-cloud image and interpolating range valuesbetween points of light in the point-cloud image, wherein the patternprojector and the range camera are spatially offset; at least one deviceconfigured to move the dimensioning system and/or the object so thatthere is relative movement between the dimensioning system and theobject, and the range camera's field-of-view contains a differentportion of the object; and a processor communicatively coupled to thepattern projector and the range camera, wherein the processor isconfigured by software to: trigger the range camera to capture aplurality of range images, wherein in each range image of the pluralityof range images, each pixel of the range image represents a distancefrom the range camera to a respective point in the range camera'sfield-of-view; gather information as the spatial relationship betweenthe range camera and the object is changed, and the information isselected from the group consisting of tracking information and mappinginformation; combine the plurality of range images to create a compositerange-image by image-stitching the plurality of range images using theinformation gathered as the spatial relationship between the rangecamera and the object is changed; and dimension the object using thecomposite range-image, wherein dimensioning the object using thecomposite range-image comprises creating a minimum bounding box thatsurrounds the object; and return the dimensions of the minimum boundingbox as dimensions of the object.
 13. The dimensioning system of claim12, wherein the processor is configured by software to adjust thespatial offset to change a resolution at which range differences may bedetected.
 14. The dimensioning system of claim 12, wherein theimage-stitching comprises simultaneous localization and mapping (SLAM).15. The dimensioning system of claim 14, wherein the simultaneouslocalization and mapping comprises: detecting features in a capturedrange image; and comparing the detected features to features detected inpreviously captured range image to update a position of the dimensioningsystem.
 16. The dimensioning system of claim 15, wherein the processoris configured by software to use the updated position of thedimensioning system to combine the plurality of range images.
 17. Thedimensioning system of claim 12, wherein the dimensioning system ishandheld.